Apparatus and Method for Automatic Detection of Diaphragm Coating or Surface Contamination for Capacitance Diaphragm Gauges

ABSTRACT

A system and a method detect contamination of a diaphragm in a capacitance diaphragm gauge wherein a contaminated diaphragm deflects less in the presence of pressure than an uncontaminated diaphragm. The system and method measure a base pressure. A DC voltage is applied between the diaphragm and a fixed electrode to cause the diaphragm to deflect to simulate an effective pressure. The system and method measure a combined pressure caused by the base pressure and the effective pressure. The system and method subtract the base pressure to determine the effective pressure caused by the static diaphragm deflection. If the measured effective pressure is less than an acceptable effective pressure, the system and method determine that the diaphragm is contaminated.

RELATED APPLICATIONS

The present application claims the benefit of priority under 35 USC§119(e) to U.S. Provisional Application No. 61/757,922 filed on Jan. 29,2013, which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is in the field of capacitance diaphragm gaugeswhich measure pressure based on the deflection of a diaphragm.

2. Description of the Related Art

Absolute capacitance diaphragm gauges (CDGs) measure pressure by sensingthe capacitance change associated with deflection of a diaphragm wherebyone side of the diaphragm (“the Px side”) is exposed to the pressure tobe measured (Px) and the other side of the diaphragm is exposed to asealed reference vacuum cavity in which an ultrahigh vacuum (e.g., lessthan 10⁻⁹ Torr) has been created prior to the sealing of the referencecavity.

The CDG measures capacitance between a diaphragm and one or more fixedelectrodes housed in the reference vacuum cavity. When the pressure onthe Px side of the diaphragm is higher than the pressure in thereference vacuum cavity, the diaphragm deflects in the direction of thefixed electrode (or electrodes), which increases the measuredcapacitance. As the pressure on the Px side of the diaphragm decreases,the pressure differential across the diaphragm diminishes and thediaphragm moves away from the fixed electrode (or electrodes) in thereference vacuum cavity, which reduces the measured capacitance.

As the pressure on the Px side of the diaphragm approaches the pressurein the reference vacuum cavity, the pressure differential across thediaphragm becomes sufficiently small as to be considered as the “zeropoint” for the CDG. This fixed zero point is established during thecalibration of the CDG and is used as a reference in subsequent pressuremeasurements.

CDGs are commonly used to the measure pressure in vacuum chambers inwhich thin or thick films of material are deposited on a substrate. Onecommon example of usage is to measure pressure during the deposition ofmaterials onto the surface of silicon wafers during the fabrication ofsemiconductor devices. CDGs are quite useful in vacuum depositionprocesses that utilize multiple gasses because capacitance diaphragmgauges are highly accurate and are able to measure absolute pressureindependent of gas composition. Unfortunately, the same characteristicsof the CDG that enable the CDG to operate in the pressure regimes inwhich vacuum deposition is typically carried out also make the CDGextremely sensitive to any form of contamination or coating that findsits way onto the surface of the diaphragm. Compounding the problem isthe fact that the diaphragm of a CDG cannot be inspected withoutremoving the CDG from the system. Thus, the user of a conventional CDGhas no nondestructive way of looking into the CDG to determine whetherthe surface of the diaphragm has been contaminated by any type ofdeposition of material on its surface.

Diaphragm contamination or coating can negatively impact the sensitivityand accuracy of the CDG and can also result in a shift in the zero pointof the CDG. Several other commonly encountered phenomena can also impactthe sensitivity, the accuracy and the zero point of the CDG. Thus, ithas heretofore been impossible for a user to detect the occurrence ofdiaphragm coating or contamination in real time and in-situ. As aresult, users of CDGs have attempted to mitigate the chance of diaphragmcontamination or coating by elevating the temperature of the diaphragm.While this technique has long been used and has a positive effect, thetechnique has not eliminated the occurrence of diaphragm contaminationor coating. CDGs are being used more frequently in processes, such assemiconductor wafer processing, that are extremely sensitive to minorinaccuracies in the vacuum measurement. Further, the effects ofdiaphragm contamination or diaphragm coating on the accuracy andrepeatability of the CDG are known to be significant enough to impactprocess results and process yields.

SUMMARY OF THE INVENTION

A need exists to detect the occurrence of diaphragm contamination orcoating in real time and in-situ so that the user can take correctiveaction. The system disclosed and claimed herein is responsive to theneed.

An aspect of embodiments disclosed herein is a method for detectingcontamination of the diaphragm of a capacitance diaphragm gauge (CDG)that includes a diaphragm and at least one fixed electrode wherein thecapacitance between the diaphragm and the at least one fixed electrodeis responsive to a pressure applied to the CDG. The method applies afirst pressure to the CDG and determines a first pressure value whilethe first pressure is applied to the CDG. The method then applies a DCvoltage between the diaphragm and the at least one fixed electrode tocause deflection of the diaphragm. The DC voltage is applied while thefirst pressure is applied to the CDG. The method determines a secondpressure value while the DC voltage is applied between the diaphragm andthe at least one fixed electrode. The method compares the secondpressure value with the first pressure value to determine a differencein pressure values resulting from the deflection caused by the appliedDC voltage. The method determines that the diaphragm is contaminatedwhen the difference in pressure values is less than an acceptabledifference in pressure values. In certain embodiments of the method, theDC voltage applied between the diaphragm and the at least one fixedelectrode causes the diaphragm to deflect toward the at least one fixedelectrode to increase the capacitance between the diaphragm and the atleast one fixed electrode.

Another aspect of embodiments disclosed herein is a contaminationdetection system for a capacitance diaphragm gauge (CDG). The CDGincludes a diaphragm and at least one fixed electrode. The capacitancebetween the diaphragm and the at least one fixed electrode is responsiveto a pressure applied to the CDG that deflects the diaphragm withrespect to the at least one fixed electrode. The system comprises asource of a DC voltage and a switch. The switch selectively applies theDC voltage between the diaphragm and the at least one fixed electrode inthe CDG. The diaphragm is responsive to the applied DC voltage todeflect the diaphragm with respect to the at least one fixed electrode.A contamination test controller has an output that selective enables theswitch and has an input that receives pressure values responsive to thedeflection of the diaphragm with respect to the at least one fixedelectrode. The contamination test controller compares a first pressurevalue before enabling the switch with a second pressure value whileenabling the switch to determine a difference between the first andsecond pressure values. The contamination test controller determines thepresence of unacceptable contamination when the difference in the firstand second pressure values is less than a predetermined pressuredifference. In certain embodiments, the system further includes anotification unit coupled to the contamination test controller, which isactivated when the contamination test controller determines the presenceof unacceptable contamination. In certain embodiments, the DC voltageapplied between the diaphragm and the at least one fixed electrodecauses the diaphragm to deflect toward the at least one fixed electrodeto increase the capacitance between the diaphragm and the at least onefixed electrode.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments in accordance with aspects of the present invention aredescribed below in connection with the attached drawings in which:

FIG. 1 illustrates a front perspective view of an exemplary capacitancediaphragm gauge (CDG), which is installable into a pneumatic system (notshown) to measure the pressure within the system;

FIG. 2 illustrates a rear perspective view of the CDG of FIG. 1 which isrotated 180° from the view in FIG. 1;

FIG. 3 illustrates a cross-sectional view of the CDG taken along theline 3-3 in FIG. 1, wherein the diaphragm appears undeflected in solidlines and appears in first and second deflected positions in dashedlines;

FIG. 4 illustrates a cross-sectional view of the CDG of FIG. 3 with alayer of contamination on the surface of the diaphragm in theundeflected position and the two deflected positions;

FIG. 5 illustrates a basic pressure monitoring system that monitors thatthe capacitance of the variable capacitor formed by the diaphragm andthe fixed electrode of FIG. 3 to determine the deflection of thecapacitor and thereby determined the pressure applied to the diaphragm;

FIG. 6 illustrates an improved pressure monitoring system for monitoringthe capacitance of the variable capacitor formed by the diaphragm andthe fixed electrode of FIG. 3 when subjected to contamination asillustrated in FIG. 5, the system further including a high voltagesource, a voltage switch, a contamination test controller and anotification unit;

FIG. 7 illustrates a flow chart of the operation of the system of FIG.6; and

FIG. 8 illustrates a second flow chart of the operation of the system ofFIG. 6.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The improvements to capacitance diaphragms are disclosed herein withrespect to exemplary embodiments of a system and a method. Theembodiments are disclosed for illustration of the system and the methodand are not limiting except as defined in the appended claims. Althoughthe following description is directed to a particular embodiment of acapacitance diaphragm gauge, it should be understood that the disclosedsystem and method can be applied to other embodiments of capacitancediaphragm gauges.

FIG. 1 illustrates a front perspective view of an exemplary capacitancediaphragm gauge (CDG) 100, which is installable into a pneumatic system(not shown) to measure the pressure within the system. In particular,the CDG is used to measure very low pressures resulting from evacuationof the pneumatic system. FIG. 2 illustrates a rear perspective view ofthe CDG of FIG. 1 which is rotated 180° from the view in FIG. 1. FIG. 3illustrates a cross-sectional view of the CDG taken along the line 3-3in FIG. 1.

In the illustrated embodiment, the CDG 100 comprises a hollow, generallycylindrical body structure 110, which extends between a first endsurface 112 (FIG. 1) and a second end surface 114 (FIG. 2). A firstcylindrical tube 120 extends from the first end surface. The firstcylindrical tube provides pneumatic access to a first inner cavity 122(FIG. 3) of the CDG. The first cylindrical tube is connectable to thepneumatic system (not shown) to allow the pressure of the system to beapplied to the first inner cavity.

As shown in FIG. 2, a diaphragm 130 within the cylindrical bodystructure 110 separates the first inner cavity 122 from a second innercavity 132. The diaphragm is sealed around its peripheral edges withrespect to an inner surface 134 of the cylindrical body structure sothat the first inner cavity is pneumatically isolated from the secondinner cavity by the diaphragm. The diaphragm is also electricallyconnected to the cylindrical body structure, which is electricallyconnected to a ground reference, as discussed below.

In certain embodiments, the diaphragm 130 comprises Inconel 750 oranother suitable material. In certain embodiments, the diaphragm has athickness that can range from approximately 0.001 inch (0.025 mm) toapproximately 0.015 inch (0.38 mm). The first inner cavity 122 alsoincludes a baffle 136 that is positioned between the diaphragm and thefirst cylindrical tube 120. The baffle reduces the deposition ofcontaminants onto the surface of the diaphragm that faces the firstinner cavity.

An electrode assembly 140 is positioned within the second inner cavity132 between the diaphragm 130 and the second end surface 114. Theelectrode assembly comprises a mounting structure 142, which is securedto the inner surface 134 of the cylindrical body structure 110. Themounting structure of the electrode assembly is not sealed around theperipheral edges. Accordingly, both sides of the electrode assembly areat the same pressure within the second inner cavity. At least oneelectrode 144 is mounted on one side of the electrode assembly mountingstructure. In particular, the electrode is mounted on the side of themounting structure that faces the diaphragm. The electrode iselectrically connected through the mounting structure. A conductor 146extends from the mounting structure to a port 150 that extends throughthe second end surface 114 of the cylindrical body structure 110. Theport 150 includes a second cylindrical tube 152 that extends outwardlyfrom the second end surface. The conductor extends beyond the end of thesecond cylindrical tube. The conductor extends through a plug 154 thathermetically seals the second cylindrical tube around the conductor.

Although described herein with respect to one electrode on the electrodeassembly, one skilled in the art will appreciate that the electrodeassembly may include more than one electrode. See, for example, U.S.Pat. No. 4,823,603 to Ferran et al., which discloses two concentricfixed electrodes. U.S. Pat. No. 4,823,603 is incorporated herein byreference.

In the illustrated embodiment, a central portion 160 of the second endsurface 114 extends outwardly to form an extended cavity portion 162 ofthe second inner cavity 132. The extended portion of the second innercavity houses a getter 164. The getter functions in a conventionalmanner to remove small amounts of gas that may be released by the innersurface of the second inner cavity.

A third cylindrical tube 170 extends from the second end surface 114 ofthe cylindrical body structure 110. Initially, the entire length of thethird cylindrical tube is uniformly cylindrical. The third cylindricaltube is connected to a vacuum evacuation system (not shown) to evacuatethe gases from the second inner cavity 132 to create a desired lowpressure within the second inner cavity. After the evacuation process iscompleted, an end portion 172 of the third cylindrical tube is crimpedas shown in FIG. 1 to seal the second inner cavity to maintain theevacuated condition of the second inner cavity.

As illustrated in the cross-sectional view of FIG. 3, the diaphragm 130is a thin metallic plate that separates the first inner cavity 122 fromthe second inner cavity 132. As discussed above, the second inner cavityis evacuated so that the absolute pressure within the second innercavity is very low (e.g., approximately 10⁻⁹ Torr). The pressure withinthe first inner cavity is determined by the pressure Px of the system(not shown) to which the first cylindrical tube 120 is connected. Whenthe pressure within the first inner cavity is substantially equal to thepressure within the second inner cavity, the diaphragm will not bedeflected and will maintain the substantially flat shape shown by thesolid cross-hatched profile (labeled as 130 in FIG. 3). If the pressurePx on the system side of the diaphragm (i.e., the pressure in the firstinner cavity) exceeds the pressure in the second inner cavity, thecenter of the diaphragm will be deflected toward the second inner cavityand the diaphragm will bow into the second inner cavity as illustratedby a first dashed cross-hatched profile 130′ in FIG. 3. If the pressurePx on the system side of the diaphragm is less than the pressure in thesecond inner cavity, the center of the diaphragm will be deflectedtoward to the first inner cavity and the diaphragm will bow into thefirst inner cavity as illustrated by a second dashed cross-hatchedprofile 130″ in FIG. 3. In each case, the amount of the deflection willbe determined by the pressure differential between the first and secondinner cavities. The amount of deflection is also determined in part bythe material properties of the diaphragm (e.g., the stiffness of thediaphragm).

As is well known in the art, the diaphragm 130 forms a first, movableplate of a variable capacitor. The electrode 144 on the electrodesupport structure 142 forms a second, fixed plate of the variablecapacitor. When the diaphragm 130 is in the undeflected initial state,the capacitance of the variable capacitor has a first (initial) valuedetermined by the initial distance between the diaphragm and theelectrode. When the pressure Px increases, the diaphragm is deflectedtoward the second inner cavity and thus toward the fixed electrode asillustrated by the first dashed cross-hatched profile 130′. Thedeflection reduces the distance between the diaphragm and the electrode,which increases the capacitance of the variable capacitor. When thepressure Px decreases, the diaphragm is deflected toward the first innercavity and thus away from the fixed electrode as illustrated by thesecond dashed cross-hatched profile 130″. The deflection increases thedistance between the diaphragm and the electrode, which decreases thecapacitance of the variable capacitor. As discussed below, thecapacitance is monitored and the increases and decreases in capacitanceare used to determine corresponding increases and decreases in thesystem pressure Px. The CDG is initially calibrated by monitoring thechanges in capacitance as a plurality of known values of the pressure Pxare applied to the CDG.

FIG. 4 illustrates a simplified exemplary system 200 for monitoring thecapacitance of the variable capacitor formed by the diaphragm 130 andthe fixed electrode 144 of FIG. 3. The system comprises a firstcapacitor 210 and a second capacitor 212. The first capacitor comprisesthe variable capacitor formed by the diaphragm and the fixed electrode.Accordingly, a first electrode (the diaphragm) of the first capacitor isidentified with the reference number 130, and a second electrode (thefixed electrode) of the first capacitor is identified with the referencenumber 144. The second capacitor is a conventional fixed capacitor. Thesecond capacitor has a first electrode 214 and a second electrode 216.

The first electrode 130 of the first capacitor 210 and the firstelectrode 214 of the second capacitor 212 are connected to a groundreference 218. The second electrode 144 of the first capacitor isconnected to a first terminal 224 of a center-tapped output (secondary)winding 222 of a transformer 220. The second electrode 216 of the secondcapacitor is connected to a second terminal 226 of the output winding ofthe transformer. A center-tap terminal 228 of the output winding of thetransformer provides a signal output on a line 230.

In the illustrated embodiment, the first electrode (diaphragm) 130 ofthe first (variable) capacitor 210 is mechanically and electricallyconnected to the cylindrical body structure 110. The cylindrical bodystructure is electrically connected to the ground reference 218 wheninstalled in the system having the pressure to be measured, thusproviding the electrical connection of the diaphragm to the groundreference. The second electrode 144 of the first (variable) capacitor isconnected to the second terminal of the transformer via the conductor146 of FIG. 3.

In the illustrated embodiment, the capacitance of the second capacitor212 is fixed. The capacitance of the second (fixed) capacitor isselected to be approximately equal to the initial capacitance betweenthe diaphragm 130 and the fixed electrode 144 (e.g., the initialcapacitance of the first (variable) capacitor 210) when the systempressure Px in the first inner cavity 122 is approximately equal to thepressure in the second inner cavity 132 as discussed above with respectto FIG. 3.

The transformer 220 has an input (primary) winding 240 having a firstterminal 242 and a second terminal 244. The first terminal is connectedto the ground reference 218. The second terminal is connected to a highfrequency signal source 250 operating, for example, at a frequency ofapproximately 50 kilohertz.

The electrical conductor 230 connects the center tap 228 of the outputwinding 222 of the transformer 220 to an input 254 of an AC pressuremeasuring circuit 250 via an AC coupling capacitor 252. The AC pressuremeasuring circuit provides an output signal (OUTPUT) on an output signalline 256.

In the illustrated embodiment, the AC pressure measuring circuit 250comprises an amplifier 260 and a demodulator 262. The signal on thecenter tap 228 of the output winding 222 of the transformer 220 isapplied to an input 270 of the amplifier via the AC coupling capacitor252. The amplifier preferably has a very high input impedance so thatsubstantially zero current flows into the input of the amplifier. Anoutput 272 of the amplifier provides an amplified output signal to aninput 274 of the demodulator. An output 276 of the demodulator providesthe output signal on the output signal line 256. The output signal isresponsive to the variations in the capacitance of the first (variable)capacitor 210. Accordingly, the output signal varies in response tochanges in the system pressure Px.

The signal generated by the high frequency signal source 250 is appliedto the input (primary) winding 240 of the transformer 220. The appliedsignal is coupled to the secondary winding 222 and induces a highfrequency voltage across the secondary winding. The induced voltage isapplied across the series connection of the first (variable) capacitor210 and the second (fixed) capacitor 212. The voltage across eachcapacitor is inversely proportional to the respective capacitance of thecapacitor. Since the capacitance of the second (fixed) capacitor issubstantially constant, the voltage across the first (variable)capacitor varies in accordance with the deflection of the diaphragm 130caused by differential pressure across the diaphragm between the firstinner cavity 122 and the second inner cavity 132 of the CDG 100. Becauseone electrode of each of each capacitor is electrically connected to theground reference 218, a difference in the voltages across the twocapacitors appears as a voltage differential across the output windingbetween the first input terminal 224 and the second input terminal 226of the output winding of the transformer.

The voltage differential across the output winding 222 of thetransformer 220 causes a voltage to appear on the center tap 228 of theoutput winding that is referenced to the ground reference 218 and thatis proportional to the differences in the capacitance between the first(variable) capacitor 210 and the second (fixed) capacitor 212.

The voltage on the center tap 228 of the output winding 222 of thetransformer 220 is applied via the conductor 230 and the AC couplingcapacitor 252 to the input 270 of the amplifier 260. The amplifieramplifies the center tap voltage and provides the amplified signal as anoutput signal on the output 272. The output signal from the amplifier isa time-varying signal at the frequency of the signal source 250 with anamplitude that is proportional to the difference in capacitance of thefirst (variable) capacitor 210, which varies in response to changes inthe pressure differential across the diaphragm 130. Accordingly, theamplitude of the time-varying signal output of the amplifier changes inresponse to changes in the pressure differential across the diaphragm.

The time-varying signal generated by the amplifier 260 is demodulated bythe demodulator 262 in a conventional manner to provide the outputsignal on the output signal line 256 having a DC voltage levelcorresponding to the pressure differential across the diaphragm 130. TheAC pressure measuring circuit is calibrated to equate the variations inthe AC voltage to the absolute pressure (Px) applied to the diaphragm.In one embodiment, the demodulator comprises a synchronous demodulatorknown to the art.

FIG. 5 illustrates the problem caused by contamination of the diaphragm130 of the CDG 100 shown in FIGS. 1-3. In particular, FIG. 5 correspondsto the cross-sectional view of FIG. 3, and like elements in FIG. 5 areidentified with the same reference numerals as used in FIG. 3. Theresult of diaphragm contamination is shown as a thin layer 300 ofmaterial deposited on the surface of the diaphragm facing the firstinner cavity 122. Although shown as a uniform layer of contamination, itshould be understood that the actual contamination on a diaphragm maynot be uniform. For example, the effect of the barrier 136 may cause thecontamination to be more extensive at the peripheral edges of thediaphragm that at the central portion. The contamination is furtherrepresented as a layer 300′ on the surface of the deflected first dashedcross-hatched profile 130′ and as a layer 300″ on the surface of thedeflected second dashed cross-hatched profile 130″ in FIG. 5. Asdiscussed above, the surface contamination affects the properties of thediaphragm such that, for example, a pressure differential that causesthe diaphragm to deflect by a first amount when the diaphragm is new anduncontaminated will cause the diaphragm to deflect by a lesser amountwhen the diaphragm becomes contaminated. Thus, a change in capacitancecaused by the same pressure differential will be less for a contaminateddiaphragm than for an uncontaminated diaphragm. Accordingly, a pressuredifferential that would have produced a particular output signal(pressure reading or pressure value) when the CDG 100 was firstinstalled will produce a different output signal (pressure reading orpressure value) when the diaphragm is contaminated. Although a smallamount of contamination will not significantly affect the pressurereading, the pressure reading will become less accurate as thecontamination increases. Eventually, the contamination will increase toa level that the pressure reading is no longer sufficiently accurate tobe used to control the system into which the CDG is installed. Since thelevel of contamination cannot be determined from the outside of thesealed CDG, a nondestructive system and method are needed to determinewhen the contamination has increased to a level that the CDG is nolonger sufficiently accurate and the CDG needs to be replaced.

FIG. 6 illustrates an improved pressure monitoring system 400 thatoperates by monitoring the capacitance of the variable capacitor formedby the diaphragm 130 and the fixed electrode 144 of FIGS. 3 and 5 whensubjected to contamination illustrated in FIG. 5. The improvedmeasurement system of FIG. 6 includes elements that are described abovewith respect to the system illustrated in FIG. 4. Accordingly, likeelements are identified with reference numbers corresponding to thereference numbers in FIG. 4. The elements of the measurement system inFIG. 6 up to and including the AC pressure measuring circuit 250 aresimilar to the corresponding components in the previously describedmeasuring system and are not described again in detail. Furthermore, thedetails of the AC measuring circuit are already shown in FIG. 4 and arenot shown again in FIG. 6.

Unlike the measurement system 200 of FIG. 4, the improved measurementsystem 400 of FIG. 6 includes a high voltage DC power supply 410 and ahigh voltage DC switch 420. The DC voltage supply provides a DC voltage(V_(DC)) of a known fixed magnitude (e.g., 300 volts DC) on an output430. The DC voltage is provided as an input to the high voltage switch.The DC voltage is selectively provided on an output 440 of the highvoltage switch in response to a control signal (DC CONTROL) applied toan input 442 of the high voltage switch. The control signal is producedby an output signal from a digital output (DIG OUT) port 452 of acontamination test controller 450 described below. The output of thehigh voltage switch is connected to the electrical conductor 230 and isthus connected to the center tap 228 of the output winding 222 of thetransformer 220. The output of the high voltage switch is also connectedto the ground reference 218 via a bleed resistor 460.

The AC pressure measuring circuit 250 in the system 400 of FIG. 6operates as described above to measure the AC voltage developed betweenthe center tap of the secondary winding and the common ground and togenerate a DC voltage on the output signal line 256 that is responsiveto the changes in capacitance resulting from the deflection of thediaphragm 130 caused by the pressure (Px) applied to the diaphragm.

The DC voltage supply 410 and the high voltage switch provide a systemand method for testing whether the surface of the diaphragm 130 iscontaminated such that the magnitudes of the deflections of thediaphragm in response to pressure changes are no longer sufficientlyconsistent with the magnitudes of the deflections when the CDG 100 wasinitially calibrated. When the high voltage switch is enabled by thecontamination test controller 450, the DC voltage from the DC voltagesupply is applied to the center tap 228 of the output winding 222 of thetransformer 220. The DC voltage is coupled through the respective halvesof the output winding to the respective first electrodes 144, 214 of thetwo capacitors 210, 212 connected to the first end terminal 224 and thesecond end terminal 226, respectively, of the output winding. The DCvoltage is isolated from the AC pressure measuring circuit 250 by thedecoupling capacitor 252 at the input to the AC pressure measuringcircuit so that the DC voltage does not affect the operation of the ACpressure measuring circuit.

The DC voltage applied to the center tap 228 of the output winding 222of the transformer 220 is applied across the first capacitor 210 betweenthe first end terminal 224 of the transformer and the ground reference218. The DC voltage is also applied across the second capacitor 212between the second end terminal 226 and the ground reference. The DCvoltage applied across the second (fixed) capacitor does not affect thecapacitance of the capacitor. In contrast, the DC voltage applied to thesecond (variable) capacitor 210 produces an electrostatic force thatcauses the diaphragm 130 to deflect by an amount responsive to the DCvoltage. The applied DC voltage causes the diaphragm to deflect into thesecond inner cavity 132 toward the fixed electrode (or electrodes) 144,which increases the capacitance in a similar manner to the increase incapacitance caused by an increase in the applied pressure (Px).Preferably, the DC voltage is applied when the applied pressure (Px) isset to a “system zero point pressure” that may be unique to the systemin which the CDG is installed. For example, the system zero pointpressure may be obtained when the system is pumped down to a known basepressure before beginning a processing step. The system zero pointpressure may be in the same general pressure range as the factory zeropoint pressure applied during the original calibration of the CDG (e.g.,approximately 10⁻⁹ Torr in one embodiment).

While the pressure Px is pumped down to the system base pressure, afirst pressure reading is taken to establish a current base pressuremeasurement value. The current base pressure measurement value isrepresented by the polarity and amplitude of a first output signal onthe output signal line 256 of the AC pressure measuring circuit 250. Theoutput from the AC pressure measuring circuit is provided as an input tothe contamination test controller 450. Then, the switched DC voltage isapplied via the high voltage switch 420, and a second pressure readingis taken to obtain a second pressure measurement value. Thus, the ACpressure measuring circuit generates a second output signal having apolarity and magnitude corresponding to the combined effects of thesystem base pressure and the “effective pressure” caused by thedeflection induced by the applied DC voltage. The second output signalis also provided to the contamination text controller. The contaminationtest controller determines a difference between the second pressurereading and the first pressure reading as the effective pressureresulting from the deflection of the diaphragm caused by the DC voltage.The effective pressure caused by the application of the high DC voltageis also determined at the time of the original installation of a new CDGinto a system when the CDG 100 has an uncontaminated or uncoateddiaphragm. The contamination test controller compares the currenteffective pressure caused by the application of the high DC voltageafter a period of use of the CDG to the original effective pressure. Ifthe current effective pressure is sufficiently different from theoriginal effective pressure, the contamination test controllerdetermines that the CDG is considered to be sufficiently contaminated towarrant replacement of the CDG with a new CDG. The magnitude of thedifference in the effective pressure readings that is sufficient towarrant replacement of the CDG can be selected by the user in accordancewith the criticality of the system in which the CDG is installed. Formore critical applications, the acceptable pressure difference may bequite small such the CDG is replaced when the contamination first formson the diaphragm and causes a small pressure difference. For lesscritical applications, the acceptable pressure difference may be largerto allow the contamination to build up on the diaphragm to a greaterextent before replacing the CDG.

The improved system described above provides an apparatus and a methodfor detecting diaphragm contamination and or diaphragm coating in situand in real time. As described above, the apparatus and method sensechanges in the deflection characteristics of the diaphragm 130 caused bythe presence of contamination or coating on the diaphragm. As describedabove, the apparatus includes circuitry (the DC voltage supply 410 andthe high voltage switch 420) that introduces a precise DC voltagebetween the diaphragm and the capacitance measuring electrode 144 withinthe reference vacuum cavity on command. The electrostatic force createdby this DC voltage causes the diaphragm to be attracted to thecapacitance measuring electrode (or electrodes in the case of a dualelectrode device). The attractive force generated by the applied DCvoltage causes the diaphragm to deflect in the direction of theelectrode (or electrodes), thus reducing the spacing between thediaphragm and the electrode (or electrodes). The reduced spacing resultsin a change in the measured capacitance. The magnitude of the deflectionof an uncoated or uncontaminated diaphragm and the resultant capacitancechange for any given applied DC voltage is highly repeatable.

The CDG 100 is characterized at the time of manufacture by applying aplurality of DC voltages of known magnitude between the diaphragm 130and the fixed electrode 144 and measuring the capacitance changes causedby the deflection. The calibration and the deflection characteristicsare stored in a memory of the contamination test controller 450. Oncethis initial characterization has been performed at the factory, theuser of the device is able to perform an in-situ diaphragm diagnosticroutine at any time the device is not being used to measure pressure.The diagnostic routine can be triggered by a customer-generated command.The diagnostic routine activates (e.g., switches) the large DC voltage(e.g., 300 volts) which is applied between the diaphragm and theelectrode (or electrodes) to induce the static deflection of thediaphragm. While the diaphragm is thus deflected, the capacitancebetween the diaphragm and the electrode (or electrodes) is measuredusing an AC voltage in a conventional manner. The measured capacitanceassociated with the induced deflection is compared to the expectedcapacitance change as initially detected for the same DC voltage appliedat the time of the original manufacture and calibration of the CDG. As acoating or other contamination develops on the diaphragm surface, theamount of deflection and the resultant measure of capacitance shift inmagnitude. In particular, greater contamination or coating causes asmaller diaphragm deflection at a given applied voltage. The smallerdiaphragm deflection results in a larger spacing between the diaphragmand the electrode (or electrodes), which causes the measured capacitanceto be less than the measured capacitance during the calibration process.The degree to which the measured capacitance is reduced is used todetermine when repair or replacement of the CDG is required. Themeasured capacitance is also used to monitor the deflectioncharacteristics of the diaphragm over time. The monitored deflectioncharacteristics enable the user of the CDG to set alarms or to establishboundary conditions in the determination of appropriate maintenanceintervals.

After selected periods of actual use (e.g., after a selected number ofhours or days), the high voltage switch 420 can be selectively enabledwhen the pressure (Px) of the system is again drawn down to the systembase pressure so that the pressure at the input of the CDG is at or nearthe “system zero point pressure” of the CDG. The pressure is againmeasured by first measuring the first pressure prior to applying the DCvoltage and then measuring the second pressure while applying the DCvoltage. The difference between the two pressures should be within anacceptable range of the difference determined when the CDG wasoriginally installed. As the diaphragm becomes contaminated or thediaphragm's surface becomes coated, the deflection of the diaphragmcaused by the DC voltage reduces, which causes a corresponding reductionin the difference between the two measured pressures. The procedure isrepeated to periodically compare the currently measured effectivepressure difference to the original effective pressure difference. Whenthe difference in the two pressure readings becomes sufficiently smallto indicate that contamination or coating on the diaphragm hassubstantially affected the measured effective pressure difference, theCDG can be removed from service and replaced with a new CDG. It shouldbe understood that the system does not have to be pumped down to thesame absolute base pressure each time the two pressure readings aretaken. Rather, as long as the system is pumped down to a current basepressure in the same range of magnitudes as the system base pressurewhen the CDG was first installed (e.g., around 10⁻⁹ Torr), thedifference between the two pressure readings during a periodic test willaccurately represent the effective pressure caused by the deflection ofthe diaphragm in response to the applied DC voltage.

The contamination test controller 450 of FIG. 6 is implemented in oneembodiment as a microcontroller or other integrated circuitry. Forexample, in one embodiment, a microcontroller includes an analog input(AN IN) port 470 that receives the output signal on the output signalline 256 from the AC pressure measuring circuit 250. The microcontrolleradvantageously includes internal analog-to-digital conversion circuitryto convert the value on the analog input to a digital value forprocessing within the microcontroller. The digital output port 452 ofthe microcontroller provides an output signal at a first level (e.g., alogical “1”) to enable the high voltage switch 420 and provides anoutput signal at a second level (e.g., a logical “0”) to disable thehigh voltage switch.

The microcontroller within the contamination test controller 450 furtherincludes a second digital output port 480, which is connected to theinput 492 of a notification unit 490. The notification unit may be assimple as an LED or an audible device that is selectively activated toindicate an error, or the notification unit may be a part of overallcontrol and display (e.g., a graphical user interface) used to controlthe system in which the CDG 100 is installed and to display operationalparameters of the system.

The microcontroller within the contamination test controller 450 furtherincludes internal memory for storing the pressure characteristics of theCDG 100 when initially characterized.

One exemplary mode of operation of the contamination test controller 450is illustrated by a flow chart 500 in FIG. 7. Normally, thecontamination test controller is off or is performing other tasks thatmay be related to the normal operation of the CDG 100. When the user ofthe CDG wants to initiate a contamination test while the pressure in theCDG is drawn down to the system base pressure, the user activates themicrocontroller to perform the routine illustrated by the flow chart inFIG. 7. The microcontroller may also be activated automatically toperform the routine on a periodic basis or when certain conditions aredetected.

The microcontroller within the contamination test controller 450initiates the routine in a step 510. The microcontroller first samplesthe voltage on the analog input port 470 in a block 512. Themicrocontroller saves the sampled voltage (which is converted to adigital value) as the current “system base pressure” in a block 514. Themicrocontroller then activates the digital output port 452 in a block520 to enable the high voltage switch 420 to apply the high voltage fromthe DC voltage supply 410 to the conductor 230. After activating thehigh voltage, the microcontroller again samples the voltage on theanalog input port in a block 530. In a block 532, the microcontrollersaves the sampled voltage as the “combined pressure” which is the sum ofthe “system base pressure” and the “effective pressure” caused bydeflection of the diaphragm 130. Then, in a block 540, themicrocontroller calculates the “effective pressure” caused by the DCvoltage by subtracting the previously sampled system base pressure fromthe currently sampled “combined pressure.” The calculated “effectivepressure” is stored in a block 550. In the illustrated embodiment, in ablock 552, the microcontroller compares the calculated “effectivepressure” against a stored effective pressure (or expected pressure)that was saved when the DC voltage was applied to the diaphragm duringthe above-described calibration process to determine a pressuredifference. Then, in a decision block 554, the determined pressuredifference is compared to an acceptable pressure difference. If thedetermined pressure difference is greater than an acceptable pressuredifference, the microcontroller sets an alarm or otherwise notifies theuser that the CDG is likely contaminated in a block 560 (e.g., via thenotification unit 490 of FIG. 6) and then ends the current test in ablock 562 and waits for the next initiation of the contamination test.Otherwise if the determined pressure difference is not greater than theacceptable pressure difference, the microcontroller proceeds directly tothe block 562. As discussed above, the acceptable pressure differencecan be set to a magnitude in accordance with the criticality of theenvironment in which the CDG is installed.

FIG. 8 illustrates a flow chart 600 of another description of themicrocontroller-implemented method of determining contamination of theCDG 100 by the contamination test controller 450. After initializing thetest for contamination in a block 610, the method applies a firstpressure to the CDG in a block 612. In the illustrated embodiment, thefirst pressure is the system base pressure as discussed above. While thefirst pressure is applied to the CDG, the method measures the voltage onthe analog input 470 of the contamination test controller to determine afirst pressure value. In a block 620, the method then applies a DCvoltage between the diaphragm 130 and the fixed electrode 144 byoutputting the DC control signal from the digital output port 452 of thecontamination controller to the input 442 of the high voltage switch420. The voltage from the DC voltage supply passes through the highvoltage switch to the center tap 228 of the output winding 222 of thetransformer 220 and thus to the diaphragm to cause the diaphragm todeflect, as described above. In a block 630, the method uses the voltageon the analog input of the contamination test controller to determine asecond pressure reading. In a block 632, the method determines adifference between the second pressure reading and the first pressurereading to determine an effective pressure caused by the high voltageapplied to the diaphragm. Then, in a decision block 640, the methoddetermines whether the effective pressure (i.e., the difference in thetwo pressure readings) is less than an acceptable effective pressure. Ifthe calculated effective pressure is less than an acceptable effectivepressure because the contamination of the diaphragm has reduced thedeflection of the diaphragm, the method notifies the user of likelycontamination in a block 650 (e.g., via the notification unit 490 ofFIG. 6) and then ends the test in a block 660. Otherwise, if thecalculated effective pressure is at least as much as the acceptableeffective pressure, the method ends the test in the block 660 withoutnotifying the user.

As further discussed above, the contamination test controller may beprogrammed to perform at regular intervals or in the presence of certainconditions rather than waiting for a manual initiation by a user.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that all thematter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

1. A method for detecting contamination of the diaphragm of acapacitance diaphragm gauge (CDG) that includes a diaphragm and at leastone fixed electrode wherein the capacitance between the diaphragm andthe fixed electrode is responsive to a pressure applied to the CDG, themethod comprising: applying a first pressure to the CDG; determiningfirst pressure value while the first pressure is applied to the CDG;applying a DC voltage between the diaphragm and the at least one fixedelectrode to cause deflection of the diaphragm, the DC voltage appliedwhile the first pressure is applied to the CDG; determining a secondpressure value while the DC voltage is applied between the diaphragm andthe at least one fixed electrode; comparing the second pressure valuewith the first pressure value to determine a difference in pressurevalues resulting from the deflection caused by the applied DC voltage;and determining that the diaphragm is contaminated when the differencein pressure values is less than an acceptable difference in pressurevalues.
 2. The method as defined in claim 1, wherein the DC voltageapplied between the diaphragm and the at least one fixed electrodecauses the diaphragm to deflect toward the at least one fixed electrodeto increase the capacitance between the diaphragm and the at least onefixed electrode.
 3. A contamination detection system for a capacitancediaphragm gauge (CDG), the CDG including a diaphragm and at least onefixed electrode wherein the capacitance between the diaphragm and the atleast one fixed electrode is responsive to a pressure applied to the CDGthat deflects the diaphragm with respect to the at least one fixedelectrode, the system comprising: a source of a DC voltage; a switch toselectively apply the DC voltage between the diaphragm and the at leastone fixed electrode in the CDG, the diaphragm responsive to the appliedDC voltage to deflect the diaphragm with respect to the at least onefixed electrode; and a contamination test controller having an outputthat selective enables the switch and having an input that receivespressure values responsive to the deflection of the diaphragm withrespect to the at least one fixed electrode, the contamination testcontroller comparing a first pressure value before enabling the switchwith a second pressure value while enabling the switch to determine adifference between the first and second pressure values, thecontamination test controller determining the presence of unacceptablecontamination when the difference in the first and second pressurevalues is less than a predetermined pressure difference.
 4. The systemas defined in claim 3, further including a notification unit coupled tothe contamination test controller, which is activated when thecontamination test controller determines the presence of unacceptablecontamination.
 5. The system as defined in claim 3, wherein the DCvoltage applied between the diaphragm and the at least one fixedelectrode causes the diaphragm to deflect toward the at least one fixedelectrode to increase the capacitance between the diaphragm and the atleast one fixed electrode.